Compact Pressure Sensor Terminal Design for Brake Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pressure sensors in brake systems are not compact enough, leading to increased volume in the entire product, which can result in steering issues due to tire slippage and locking of the steering system during braking.
Innovation Solution
A compact pressure sensor design featuring a terminal with a resilient portion formed through punching and bending of a metal plate, where the terminal includes a contactor and a connector soldered to the substrate, and a sensing module with a flat sensing face parallel to the housing, reducing the overall volume by optimizing the substrate and terminal configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pressure sensor design is used, then the sensor can detect brake pressure, but the sensor volume is large leading to steering system locking during braking
Solution Approach 1:
The patent merges the terminal and substrate into a single integrated component structure. The terminal is directly formed on the substrate through punching and bending operations, eliminating the need for separate terminal components and reducing overall sensor volume while maintaining electrical connection functionality.
Solution Approach 2:
The patent repositions the substrate from a perpendicular orientation to a parallel orientation relative to the sensor housing longitudinal axis. This dimensional change allows for more compact arrangement of components and reduces the overall sensor volume, preventing steering system interference during braking operations.
2Volume of stationary object
If the substrate is positioned perpendicular to the longitudinal axis, then electrical connections are easy to establish, but the sensor volume increases
Solution Approach 1:
The patent changes the substrate orientation from perpendicular to parallel with the longitudinal axis of the sensor housing. This repositioning reduces sensor volume while the terminal structure, formed by punching and bending metal plate, maintains electrical connection capability through its contactor design that engages with the substrate.
3Volume of stationary object
If a compact sensor design is implemented, then steering issues are prevented, but terminal connection reliability may be compromised
Solution Approach 1:
The patent incorporates a resilient portion in the terminal structure that can elastically deform. This dynamic feature allows the terminal to maintain reliable electrical contact despite volume reduction, as the resilient portion can flex to ensure proper engagement with the substrate while keeping the overall sensor compact.
Solution Approach 2:
The terminal is formed from metal plate material that provides both structural integrity and electrical conductivity. This composite approach ensures that even in a compact design, the terminal maintains sufficient strength and reliability for electrical connections while occupying minimal space.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The compact pressure sensor design reduces the volume of the sensor and the entire product, enhancing accuracy and preventing steering issues by minimizing tire slippage and steering lock during braking.
Implementation Method 1
a resilient portion (182) extending between the contactor (181) and the connector (184)... the resilient portion (182) is resiliently transformed by the pressing force applied to the contactor (181) by the contact point of an external device
Implementation Method 2
the connector (184) soldered to the substrate (14)
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
According to an embodiment, a pressure sensor can comprise: a sensor module including a strain gauge for measuring the pressure of gas flowing into a passage part formed therein; a substrate electrically connected to the strain gauge; a frame encompassing at least one part of the sensor module and supporting the substrate; a terminal electrically connected to the substrate and coming into contact with a contract point of an external device; a terminal holder for supporting the terminal; and a housing of which one side is connected to the housing or the frame and of which the other side encompasses at least one part of the terminal holder.